idler/tensioner pulleys

I have a '97 Plymouth Gr Voyager with a 3.0L engine. I bought it used and occasionally, if I hit a large water puddle, the serpentine belt will come off. I have ensured that the shroud/shield on the underside is all there and in place. While reinstalling the belt, I noticed that the idler pulley has a lip on each edge and the tensioner pulley is flat ( smooth). As the belt routing indicates, the belt mearly contacts the idler pulley but goes nearly half way around the tensioner pulley. Seems like the tensioner pulley should have the pulley with the lip to keep the belt in line and ON! Maybe a previous owner/garage swapped these pulleys inadvertently. I have no problem at any other time except when there's a heavy rain and I manage to plow thru a deep puddle. Anybody have the same engine/van that can verify the pulley locations? Haynes and Chilton manuals don't show clear enough pictures to determine if the pulleys are correct.

In general, the outside of the belt runs on smooth pulleys, and the inside of the belt goes on the grooved and lipped pulleys. Hope this helps.

I bit the bullet and installed a new belt tensioner with pulley. The old tensioner's pulley mounting stub was worn (?). The bearing was fine but there was some wobble to the pulley when mounted on the stub.
I want to pass along an installation hint for the belt tensioner assy.
I tried loosening the nut from around the left side (facing the engine) but there isn't enough room between the nut and the firewall, power steering hoses, etc to get a wrench or ratchet in there. I used a deep-well 15mm socket on a long extension and went from the right side of the engine (over the intake plenum). Watch out for the coil and the plug wires back there but you can get to that mounting nut that way. Once you get the nut loosened a little, you can reach around the left side and take it off with your fingers. Let it rain!

I bit the bullet and installed a new belt tensioner with pulley. The old tensioner's pulley mounting stub was worn (?). The bearing was fine but there was some wobble to the pulley when mounted on the stub.
I want to pass along an installation hint for the belt tensioner assy.
I tried loosening the nut from around the left side (facing the engine) but there isn't enough room between the nut and the firewall, power steering hoses, etc to get a wrench or ratchet in there. I used a deep-well 15mm socket on a long extension and went from the right side of the engine (over the intake plenum). Watch out for the coil and the plug wires back there but you can get to that mounting nut that way. Once you get the nut loosened a little, you can reach around the left side and take it off with your fingers. Let it rain!
I came across a similar issue a few years ago and found that the car had the incorrect belt, it was about an inch longer so the tentioner was not working properly. Did you perhaps stretch the new and old belts out next to each other and measure ? also I purchased a long wrench from the Snap-on truck which they made for serpentine work and it works great. Sounds like you have it fixed now. Good luck ... let it rain.

I am having the same problem with my 97 dodge caravan. I have had a new tentioner installed, a new belt, a new idler, and a new belt. I am still having a problem when it rains or if I drive though a puddle. Can someone please help. These were all installed by a certified mechanic. He still doesn't know what's wrong. I also had a new shield installed

If it is the 3.0l you might want to check the power steering pulley.

If it is the 3.0l you might want to check the power steering pulley.


Thanks, I wanted to let everyone that is having the same problem I am that there was a tsb out for dodge caravans for the years 1996-1999. 9(technical service bulletin) There is a faulty mounting bracket. Unfortunately- A chrysler dealer that I have been taking my van to did not know. I found out by researching the internet and a local garage. It's funny how the dealership did not know. Anyhow, the price for the part is around $50 and you can get it from a chrysler service center.